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B ENGINE

                                                                                                                                                                 A


                                                                                                                                                                 CO
                                                                                               SECTION
                                                                         ENGINE COOLING SYSTEM                                                                   C


                                                                                                                                                                 D


                                                                                                                                                                 E
                                                                CONTENTS
                               QG18DE                                           SERVICE DATA AND SPECIFICATIONS (SDS) ..... 20                          .        F
                                                                                 Capacity ................................................................. 20
                                                                                                                                                        .
PRECAUTIONS ......................................................... 3.         Thermostat ............................................................ 20
                                                                                                                                                        .
 Precautions For Liquid Gasket ................................ 3      .         Radiator ................................................................. 20
                                                                                                                                                        .        G
   REMOVAL OF LIQUID GASKET ......................... 3                .
   LIQUID GASKET APPLICATION PROCEDURE 3                               .....
PREPARATION .......................................................... 4
                                                                       .
                                                                                                               QR25DE
 Special Service Tools .............................................. 4.                                                                                         H
                                                                                PRECAUTIONS ....................................................... 21
                                                                                                                                                     .
OVERHEATING CAUSE ANALYSIS ......................... 5                 .         Precautions For Liquid Gasket .............................. 21     .
 Overheating Cause Analysis ................................... 5      .           REMOVAL OF LIQUID GASKET ........................ 21              .
COOLING SYSTEM ................................................... 7   .           LIQUID GASKET APPLICATION PROCEDURE 21                            ...          I
 Cooling Circuit ......................................................... 7
                                                                       .        PREPARATION ........................................................ 22
                                                                                                                                                     .
ENGINE COOLANT ................................................... 8   .         Special Service Tools ............................................ 22
                                                                                                                                                     .
 System Check ......................................................... 8
                                                                       .        OVERHEATING CAUSE ANALYSIS ....................... 23                .           J
   CHECKING COOLING SYSTEM HOSES ........... 8                         .         Troubleshooting Chart ........................................... 23.
   CHECKING RESERVOIR LEVEL ........................ 8                 .        COOLING SYSTEM ................................................. 25  .
   CHECKING COOLING SYSTEM FOR LEAKS..... 8                                      Cooling Circuit ....................................................... 25
                                                                                                                                                     .
   CHECKING RADIATOR ....................................... 8         .                                                                                         K
                                                                                ENGINE COOLANT ................................................. 26  .
   CHECKING RADIATOR CAP ............................... 9             .         System Check ....................................................... 26
                                                                                                                                                     .
 Refilling Engine Coolant .......................................... 9 .           CHECKING COOLING SYSTEM HOSES .......... 26                       .
WATER PUMP ......................................................... 10.           CHECKING RESERVOIR LEVEL ...................... 26                .           L
 Removal and Installation ....................................... 10   .           CHECKING COOLING SYSTEM FOR LEAKS ... 26
 Inspection ...............................................................11
                                                                       .           CHECKING RADIATOR ..................................... 26        .
THERMOSTAT AND THERMOSTAT HOUSING ..... 12                             .           CHECKING RADIATOR CAP ............................. 27            .           M
 Removal and Installation ....................................... 12   .         Refilling Engine Coolant ........................................ 27.
   REMOVAL .......................................................... 12
                                                                       .        WATER PUMP ......................................................... 28
                                                                                                                                                     .
   INSPECTION AFTER REMOVAL ...................... 12                  .         Removal and Installation ....................................... 28 .
   INSTALLATION .................................................. 13  .           REMOVAL .......................................................... 28
                                                                                                                                                     .
RADIATOR ............................................................... 14
                                                                       .           INSPECTION AFTER REMOVAL ...................... 29                .
 Removal and Installation ....................................... 14   .           INSTALLATION .................................................. 29.
   REMOVAL .......................................................... 14
                                                                       .           INSPECTION AFTER INSTALLATION ............... 29                  .
   INSTALLATION .................................................. 14  .        THERMOSTAT AND THERMOSTAT HOUSING ..... 30                           .
 Disassembly and Assembly .................................. 15        .         Removal and Installation ....................................... 30 .
   PREPARATION ................................................. 15    .           REMOVAL .......................................................... 30
                                                                                                                                                     .
   DISASSEMBLY .................................................. 15   .           INSPECTION AFTER REMOVAL ...................... 31                .
   ASSEMBLY ........................................................ 16.           INSTALLATION .................................................. 31.
 Inspection .............................................................. 18
                                                                       .        RADIATOR ............................................................... 32
                                                                                                                                                     .
COOLING FAN ........................................................ 19.         Removal and Installation ....................................... 32 .
 Disassembly and Assembly Radiator Cooling Fan 19                      ...         REMOVAL .......................................................... 32
                                                                                                                                                     .
   DISASSEMBLY .................................................. 19   .           INSTALLATION .................................................. 32.
   ASSEMBLY ........................................................ 19.

                                                                          CO-1
 Disassembly and Assembly ................................... 33       .        SERVICE DATA AND SPECIFICATIONS (SDS) .....38                           .
   PREPARATION .................................................. 33   .         Capacity .................................................................38
                                                                                                                                                        .
   DISASSEMBLY .................................................. 33   .         Thermostat .............................................................38
                                                                                                                                                        .
   ASSEMBLY ........................................................ 34.         Water Control Valve ...............................................38  .
 Inspection .............................................................. 36
                                                                       .         Radiator .................................................................38
                                                                                                                                                        .
COOLING FAN ......................................................... 37
                                                                       .
 Disassembly and Assembly ................................... 37       .
   DISASSEMBLY .................................................. 37   .
   ASSEMBLY ........................................................ 37.




                                                                          CO-2
                                              PRECAUTIONS
                                                                           [QG18DE]
PRECAUTIONS                                                                  PFP:00001
                                                                                           A
Precautions For Liquid Gasket                                                   EBS00EYR

REMOVAL OF LIQUID GASKET
q    After removing the mounting bolts and nuts, disconnect and                            CO
     remove the sealant using a seal cutter.
CAUTION:
Be careful not to damage the mating surfaces.
                                                                                           C
q    In areas where the cutter is difficult to use, use a plastic hammer
     to lightly tap the liquid gasket applied area.
CAUTION:
                                                                                           D
If for some unavoidable reason a tool such as a flat-blade
screwdriver is used, be careful not to damage the mating sur-
faces.
                                                                              PBIC0275E
                                                                                           E
LIQUID GASKET APPLICATION PROCEDURE
1.   Using a scraper, remove the old sealant adhering to the applica-
     tion surface and the mating surface.                                                  F
q    Remove the old sealant completely from the groove of the appli-
     cation surface, mounting bolts, and bolt holes.
2.   Thoroughly clean the application surface and the mating surface                       G
     to remove adhering moisture, grease and foreign material.
3.   Attach the sealant tube to the tube presser.
     Use Genuine RTV Silicone Sealant or equivalent. Refer to                              H
     GI-45, "RECOMMENDED CHEMICAL PRODUCTS AND
     SEALANTS" .
                                                                              PBIC0003E

                                                                                            I
4.   Apply the sealant without breaks to the specified location with
     the specified dimensions.
q    If there is a groove for the sealant application, apply the sealant                   J
     to the groove.

                                                                                           K


                                                                                           L
                                                                              EMA0622D



                                                                                           M
q    As for the bolt holes, normally apply the sealant inside the holes.
     Occasionally, it should be applied outside the holes.
q    Within five minutes of sealant application, install the mating
     component.
q    If the sealant protrudes, wipe it off immediately.
q    Do not retighten after the installation.
q    After 30 minutes or more have passed from the installation, fill
     the engine with the specified oil and coolant. Refer to MA-13,
     "RECOMMENDED FLUIDS AND LUBRICANTS" .
                                                                              SEM164F




                                                     CO-3
                                                       PREPARATION
                                                                                                                           [QG18DE]
PREPARATION                                                                                                                     PFP:00002

Special Service Tools                                                                                                                EBS00CH2

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
  Tool number                                                                             Description
  (Kent-Moore No.)
  Tool name
  EG17650301                                                                             Adapting radiator cap tester to radiator filler
  (J33984-A)                                                                             neck
  Radiator cap tester adapter                                                            a: 28 (1.10) via.
                                                                                         b: 31.4 (1.236) via.
                                                                                         c: 41.3 (1.626) via.
                                                                                         Unit: mm (in)

                                                                         NT564


  KV99103510                                                                             Installing radiator upper and lower tanks
  ( -- )
  Radiator plate pliers A




                                                                         S-NT224


  KV99103520                                                                             Removing radiator upper and lower tanks
  ( -- )
  Radiator plate pliers B




                                                                         S-NT225




                                                                CO-4
                                      OVERHEATING CAUSE ANALYSIS
                                                                                                                        [QG18DE]
OVERHEATING CAUSE ANALYSIS                                                                                                   PFP:00012
                                                                                                                                            A
Overheating Cause Analysis                                                                                                       EBS00CH3


                                       Symptom                                                     Check items
                                           Water pump malfunction         Worn or loose drive belt                                          CO
                                           Thermostat stuck closed            Coolant circulation
                                                                          Dust contamination or
                                                                                                                                            C
               Poor heat transfer          Damaged fins                   paper clogging                                --
                                                                          Mechanical damage
                                           Clogged radiator cooling       Excess foreign material                                           D
                                           tube                           (rust, dirt, sand, etc.)
                                           Cooling fan does not oper-
                                           ate
                                                                                                                                            E
               Reduced air flow            High resistance to fan rota-       Engine cooling fans                       --
                                           tion
                                           Damaged fan blades
                                                                                                                                            F
               Damaged radiator shroud                  --                             --                               --
               Improper coolant mixture
Cooling sys-                                            --                             --                               --
               ratio                                                                                                                        G
tem parts
malfunction    Poor coolant quality                     --                             --                               --
                                                                                                         Loose clamp
                                                                          Cooling hose                                                      H
                                                                                                         Cracked hose
                                                                          Water pump                     Poor sealing
                                                                                                         Loose
                                                                          Radiator cap                                                       I
                                                                                                         Poor sealing
                                           Coolant leaks
                                                                                                         O-ring for damage, deterio-
               Insufficient coolant                                                                      ration or improper fitting         J
                                                                          Radiator
                                                                                                         Cracked radiator tank
                                                                                                         Cracked radiator core
                                                                          Reservoir tank                 Cracked reservoir tank             K
                                                                                                         Cylinder head deterioration
                                                                          Exhaust gas leaks into
                                           Overflowing reservoir tank                                    Cylinder head gasket dete-
                                                                          cooling system                                                    L
                                                                                                         rioration



                                                                                                                                            M




                                                             CO-5
                                     OVERHEATING CAUSE ANALYSIS
                                                                                                                       [QG18DE]
                                           Symptom                                                  Check items
                                                                                                          High engine RPM under no
                                                                                                          load
                                                                                                          Driving in low gear for
                                                                          Abusive driving
                                                                                                          extended time
                                                                                                          Driving at extremely high
                                                                                                          speed
                  Over heating engine          Overload on engine
                                                                          Powertrain system mal-
                                                                          function
Except cool-                                                              Installed improper size
ing system                                                                wheels and tires                             --
parts mal-
                                                                          Dragging brakes
function
                                                                          Improper ignition timing
                                               Blocked bumper                          --
                                                                          Installed car brassiere
                                               Blocked radiator grille
               Blocked or restricted air                                               __                 Mud, debris, or paper clog-
               flow                            Blocked radiator                        --                            ging

                                               Blocked condenser
                                                                                       --
                                               Installed large fog lamp




                                                                  CO-6
                  COOLING SYSTEM
                                   [QG18DE]
COOLING SYSTEM                       PFP:21020
                                                     A
Cooling Circuit                           EBS00CH4




                                                     CO



                                                     C


                                                     D


                                                     E



                                                     F


                                                     G


                                                     H



                                                      I

                                    WBIA0132E


                                                     J



                                                     K


                                                     L



                                                     M




                       CO-7
                                         ENGINE COOLANT
                                                                                              [QG18DE]
ENGINE COOLANT                                                                                   PFP:KQ100

System Check                                                                                         EBS00CH5


WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure
fluid escaping from the radiator.
Wrap a thick cloth around the cap. Slowly push down and turn it a quarter turn to allow built-up pres-
sure to escape. Carefully remove the cap by pushing down and turning it all the way.
CHECKING COOLING SYSTEM HOSES
Check hoses for the following:
q  Improper attachment
q  Leaks
q  Cracks
q  Damage
q  Loose connections
q  Chafing
q  Deterioration
CHECKING RESERVOIR LEVEL
q   Check if the reservoir tank coolant level is within MIN to MAX
    when the engine is cool.
q   Adjust coolant level if it is too much or too little.




                                                                                                  SMA412B


CHECKING COOLING SYSTEM FOR LEAKS
To check for leakage, apply pressure to the cooling system using
Tool.
        Testing pressure    : 157 kPa (1.6 kg/cm2 , 23 psi)
WARNING:
Never remove the radiator cap when the engine is hot. Serious
burns could occur from high pressure coolant escaping from
the radiator.
CAUTION:
Higher pressure than specified may cause radiator damage.
                                                                                                  SLC756A


CHECKING RADIATOR
Check radiator for mud or clogging. If necessary, clean radiator as follows:
q  Be careful not to bend or damage the radiator fins.
q  When radiator is cleaned without removal, remove all surrounding parts such as cooling fan, radiator
   shroud and horns. Then tape the harness and connectors to prevent water from entering.
1. Apply water by hose to the back side of the radiator core vertically downward.
2. Apply water again to all radiator core surfaces once per minute.
3. Stop washing when clear water flows off the radiator.
4. Blow air into the back side of radiator core vertically downward.
    q   Use compressed air lower than 490 kPa (5 kg/cm2 , 71 psi) and keep distance more than 300 mm (11.8
        in).


                                                   CO-8
                                           ENGINE COOLANT
                                                                                                     [QG18DE]
5.   Blow air again into all the radiator core surfaces once per minute until no water sprays out.
6.   Check for leakage.                                                                                              A

CHECKING RADIATOR CAP
q    To check radiator cap, apply pressure to cap using Tool.                                                        CO
        Radiator cap relief pressure
        Standard : 78 - 98 kPa (0.8 - 1.0 kg/cm2 , 11 - 14 psi)
                                                                                                                     C
        Limit        : 59 kPa (0.6 kg/cm2 , 9 psi)


                                                                                                                     D


                                                                                                        SLC755A
                                                                                                                     E
q    Pull the negative pressure valve to open it.
q    Check that it closes completely when released.
                                                                                                                     F


                                                                                                                     G


                                                                                                                     H
                                                                                                        SMA967B


Refilling Engine Coolant                                                                                  EBS00CH6
                                                                                                                      I
Changing the engine coolant is part of the required maintenance of the engine. Refer to MA-16, "Changing
Engine Coolant" .
                                                                                                                     J



                                                                                                                     K


                                                                                                                     L



                                                                                                                     M




                                                     CO-9
                                            WATER PUMP
                                                                                       [QG18DE]
WATER PUMP                                                                                 PFP:21020

Removal and Installation                                                                           EBS00CH7




                                                                                          WLC017

CAUTION:
q  When removing water pump assembly, be careful not to get coolant on drive belt.
q  Water pump cannot be disassembled and should be replaced as a unit.
q  After installing water pump, check for leaks using radiator cap tester. Refer to CO-8, "CHECKING
   COOLING SYSTEM FOR LEAKS" .
1. Drain engine coolant.
   Refer to MA-16, "DRAINING ENGINE COOLANT" .




                                                                                             WLC007




                                                                                             SEM869F


2.   Remove front RH wheel.
3.   Remove engine side cover.
4.   Remove drive belts and idler pulley.
5.   Loosen water pump pulley bolts.
6.   Remove water pump pulley.



                                              CO-10
                                              WATER PUMP
                                                                               [QG18DE]
7.   Remove the water pump bolts.
8.   Remove the water pump.                                                                    A
     q Remove liquid gasket from water pump and mating surface of
       cylinder block using a scraper.
9.   Installation is in the reverse order of removal.                                          CO
     q When applying liquid gasket to mating surface of water pump,
       use Genuine Anaerobic Liquid Gasket or equivalent. Refer to
       GI-45, "RECOMMENDED CHEMICAL PRODUCTS AND                                               C
       SEALANTS" .
     q When filling radiator with coolant, refer to MA-17, "REFILLING             SEM859F
       ENGINE COOLANT" .                                                                       D
     q When installing drive belts, refer to MA-16, "Checking Drive Belts" .

Inspection                                                                          EBS00CH8
                                                                                               E
1.   Rotate water pump shaft, replace the water pump as necessary.
q    Check body assembly and vane for rust or corrosion.
q    Check for rough operation due to excessive end play.                                      F


                                                                                               G


                                                                                               H
                                                                                  SEM860F




                                                                                                I


                                                                                               J



                                                                                               K


                                                                                               L



                                                                                               M




                                                    CO-11
                                THERMOSTAT AND THERMOSTAT HOUSING
                                                                                                        [QG18DE]
THERMOSTAT AND THERMOSTAT HOUSING                                                                          PFP:21200

Removal and Installation                                                                                        EBS00CH9




                                                                                                          WBIA0134E

WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure
coolant escaping from the radiator.
CAUTION:
Perform when the engine is cold.
CAUTION:
Be careful not to spill coolant over the engine compartment. Use a rag to absorb any spilled coolant.
REMOVAL
1.      Drain engine coolant. Refer to MA-16, "DRAINING ENGINE COOLANT" .
2.      Disconnect the lower radiator hose.
3.      Remove water inlet thermostat housing, then remove the thermostat.
INSPECTION AFTER REMOVAL
q       Place a string so that it is caught in the valve of the thermostat
        (or water control valve) and suspend it in boiling water. It must
        be fully immersed in the water.
q       The valve opening temperature is the temperature at which the
        valve plate begins to rise from the top plate causing the thermo-
        stat to fall off of the string.
q       Continue heating the water and thermostat to check the valve lift
        (the full-open valve lift distance).
        NOTE:
        The valve lift standard temperature for the thermostat (or water
        control valve) is the reference value.                                                             SLC252B


q        After checking the valve lift, lower the water temperature and check the valve closing temperature.
        Standard Values
    Valve opening temperature       76.5



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